Method and apparatus for manufacturing display comprising light-emitting diodes

Abstract

A display incorporating light-emitting diodes, comprising a reflector which is formed in a holder. A light-emitting diode is mounted in the holder and projects into the reflector through an opening. The light-emitting doide is attached in the opening with the diode walls snugly abutting against the edges of the opening. The invention also relates to a method of manufacturing the display comprising light-emitting diodes and an installation to perform the method. Each diode is provided with two connections protected by the holder. The holder consists of surface-treated sheet metal, preferably anodized aluminium. The reflector is bowl-shaped and semispherical. Owing to the reflector a bundle of aligned beams of light is emitted from the light-emitting diode.

What I claim is: 
     
       1. An improved method of manufacturing displays incorporating light-emitting diodes, wherein said light-emitting diodes form a selected pattern and their power are enhanced by reflectors surrounding the individual light-emitting diodes, said method comprising mapping the selected pattern on a substratum,   determining a series of coordinate points on the substratum relating to the positions of the light-emitting diodes to form the selected pattern,   automatically recording the series of coordinates thus determined in computer memory means;   supplying said recorded series of coordinates from said computer memory means to control means and directly utilizing said series of recorded coordinates to successively position backing means and means for forming impressions and openings in said impressions in aligned relationship on opposite sides of a plate;   successively actuating said means for forming impressions and openings as positioned so as to thereby form said impressions and said openings in said plate substantially at each of said series of coordinates;   inserting said diodes in each of said openings; and   interconnecting said diodes in a desired manner.   
     
     
       2. Apparatus for manufacturing displays incorporating light-emitting diodes and formed with impressions in which are positioned said light-emitting diodes to form a selected pattern, said machine comprising means for determining the coordinates relating to the positions of said light-emitting diodes,   means connected to said determining means for automatically receiving and recording said coordinates, and   support means for supporting a sign blank in which aid impressions are to be formed;   first block means movably supported on first guide means in opposing relationship to one surface of said blank and second block means movably supported on second guide means in opposing relationship to another surface of said blank and aligned with said first block means, one of said first and second block means carrying an abutment surface and the other carrying stamping and punching means;   said receiving and recording means including control means operatively associated with said stamping and punching means for moving said first and second blocks in synchronized relationship and positioning said stamping and punching means and said abutment surface substantially at successive ones of said coordinate positions in response to receipt of said coordinates from said receiving and recording means and actuating said stamping and punching means to form impressions and openings in said impressions in said sign blank.